Two opposed recessed end panel carton with closure flaps



Dec. 13, 1966 R. T. ELIAS 3,291,370

TWO OPPOSED RECESSED END PANEL CARTON WITH CLOSURE FLAPS Original Filed Nov. 6, 1963 6 Sheets$heet 1 8 v Q n an R. T. ELIAS Dec. 13, 1966 TWO OPPOSED REGESSED END PANEL CARTON WITH CLOSURE FLAPS 6 Sheets-Sheet 2 Original Filed Nov. 6, 1965 8 odnh 8 INVENTOR ROBERT T. E Lms n y 1 BY (I? R. T. ELIAS 3,291,370

TWO OPPOSED RECESSED END PANEL CARTON WITH CLOSURE FLAPS Dec. 13, 1966 6 Sheets-Sheet 5 Original Filed Nov. 6, 1963 INVENT OR ROBERT T. E was BY M ATTORNEYS Dec. 13, 1966 R. T. ELIAS 3,291,370

TWO OPPOSED RECESSED END PANEL CARTON WITH CLOSURE FLAPS Original Filed NOV. 6, 1963 6 Sheets-Sheet 4 INVENTOR ROBERT T Euas I90 ATTORNEY5 R. T. ELIAS 3,291,370

TWO OPPOSED RECESSED END PANEL CARTON WITH CLOSURE FLAPS Dec. 13, 1966 6 Sheets-Sheet 5 Original Filed Nov. 6, 1963 INVENTOR ROBERT T. ELIAS Dec. 13, 1966 R. T. ELIAS 3,

TWO OPPOSED RECESSED END PANEL CARTON WITH CLOSURE FLAPS Original Filed NOV. 6, 1965 6 Sheets-Sheet 6 INVENTOR ROBERT "Y Eur-Y5 United States Patent Ofiice 3,291,376 Patented Dec. 13, 1966 Original application Nov. 6, 1963, Ser. No. 321,757.

Divided and this application Oct. 24, 1965, Ser. No.

Claims. (Cl. 229-37 This is a division of application Serial No. 321,757 filed on November 6, 1963, now No. 3,240,418.

This invention relates to a broadly applicable novel type of carton design in which a collapsible or fold-flat structure affords two opposed recessed panels and four non-recessed panels with two of these non-recessed panels affording conventional flap-type closure.

Various types of flanged containers are known in the prior art wherein the final closure of the container involves the pinching together of fins or flanges which leave all edges of the paperboard, or other material of construction, extending outwardly from the container rather than in possible contact with the contents of the container. However, such previously known types of containers had the inherent disadvantage that conventional sealing machines and conventional sealing procedures could not be used.

In the present invention, various types of flanged containers are disclosed wherein the advantages of flanged constructions still apply but in which the conventional container closure, of overlapping or at least coplanar flaps, is also incorporated. Thus, the present invention combines the advantages of a flanged container with the possible use of using container sealing machines and container sealing procedures designed for ordinary cartons.

It is an object of this invention to provide various types of flanged containers which may be closed with conventional sealing machines and sealing procedures wherein overlapping flaps may be secured together by the use of adhesives, staples or Wire stitching, or flaps which do not overlap but merely approach or just touch each other may be sealed with the use of tape.

A further object of this invention is to provide a container comprising a plurality of upstanding panels including side panels and recessed end panels, first closure flaps connected to the side panels along the top and bottom edges theerof, edge portions of the first closure flaps and edge portions of the side panels extending outwardly from the recessed end portions, and second closure flaps connected to the end panels along the top and bottom edges thereof.

Another object of this invention is to provide a container which includes a recessed end panel in which the recess is created by outwardly extending vertical and horizontal flanges wherein there is no break between a vertical flange and the adjacent horizontal flange.

Another object of this invention is to provide containers, of the type having recessed end panels, with flange forming panels connected to the recessed end panels and being disposed normal thereto, and including reinforcing means, such as wooden inserts or wire rods, disposed along the flange forming panels to provide strength therefor.

Another object of this invention is to provide a container for such contents as fragile tiles, wherein the container has a completely smooth interior and fits the contents closely in every place to prevent shifting of and damage to the contents.

Another object of this invention is to provide a flanged container wherein outwardly extending flange forming panels provide hand grips for convenient handling of the container.

Another object of this invention is to provide a rectangular container which includes eight flange-protected edges wherein the flanges may be of single, double, triple or even greater thickness, and each of the four remaining edges is protected by double thickness of the container forming material.

Another object of this invention is to provide a flange container wherein it is economical to have closure flaps of unequal length, or for that matter, to have panels of different materials if desired, or to have the same material in different grain direction.

Another object of this invention is to provide a flanged container which lends itself with great advantage to onepiece construction, but also permits the assembly of four pieces into strong containers having smooth interiors, wherein each of the four pieces could be substantially a rectangle, and since each could be cut to optimum length before assembly, there would be no wastefully long flaps, and scrap would be minimized.

Another object of this invention is to provide vertically and horizontally flanged containers wherein the columnar strength of the vertical flanges adapts the containers for stacking, one upon the other, even though the containers are not completely full; or even though the contents are fragile and cannot internally support the container; or even though the contents are of such types as coarse powder, balls, pellets, etc., which contents while not supporting a container internally will even exert a sort of hydraulic force laterally.

A further object of this invention is to provide a flanged container which is constructed of corrugated cardboard of the type having flutes therein, wherein the flutes in each of the upstanding side and end panels are vertically disposed such that the side and end panels have the necessary strength to resist vertically oriented compressive forces.

A still further object of this invention is to provide a flanged container which may be constructed of paper board, heavy paper, plastic or other similar flexible materials.

With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claimed subject matter and the several views illustrated in the accompanying drawings.

In the drawings:

FIGURE 1 is a plan view of a blank which is used in constructing one form of container in accordance with the present invention.

FIGURE 2 is a perspective view of a partially folded container which is constructed from the blank which is shown in FIGURE 1.

FIGURE 3 is a perspective view of a container formed from the blank shown in FIGURE 1, showing the container partly open.

FIGURE 4 is a perspective view of the container, similar to FIGURE 3, showing the container closed.

FIGURE 5 is an enlarged fragmentary vertical sectional view, taken on line 55 of FIGURE 4.

FIGURE 6 is an enlarged fragmentary horizontal sectional view, taken on line 6-6 of FIGURE 5, and shows the vertical orientation of the flutes in the corrugated cardboard from which the container is constructed.

FIGURE 7 is a plan view of a modified blank which is used for constructing another embodiment of the invention.

FIGURE 8 is a perspective view of a partially folded container which is constructed from the blank of FIG- URE 7.

FIGURE 8A is a perspective view of a partially folded container, similar to the view of FIGURE 8.

FIGURE 9 is a perspective view of a container which is formed from the blank of FIGURE 7, and shows one closure flap in a partially opened condition.

FIGURE 10 is an enlarged fragmentary vertical sectional view, taken on line 10--10 of FIGURE 9, and illustrates a recessed end panel which is bounded by top and bottom flanges having four thicknesses of material.

FIGURE 11 is an enlarged fragmentary horizontal sectional view, taken on line 1111 of FIGURE 10, and illustrates vertically disposed and horizontally spaced flanges which are formed of two thicknesses of material.

FIGURE 12 is a fragmentary sectional view, similar to FIGURE 10, and illustrates a modified form of fourthickness flange construction.

FIGURE 13 is a fragmentary sectional view, similar to FIGURE 12, and illustrates a modified form of triple thickness flange construction.

FIGURE 14 is a fragmentary sectional view, similar to FIGURE 13, and illustrates a modified form of double thickness flange construction.

FIGURE 15 is a fragmentary sectional view, similar to FIGURE 14, and illustrates a modified form of single thickness flange construction.

FIGURE 16 is a plan view of a modified form of blank which is used in constructing a different embodiment of this invention.

FIGURE 17 is a perspective view of partially erected container which is constructed from the blank of FIG- URE 16.

FIGURE 18 is a perspective view of a container which is constructed from the blank of FIGURE 16, and shows the closure flaps in a partially opened position.

FIGURE 19 is a perspective view, similar to FIGURE 18, and illustrates the container with the closure flaps in their closed positions.

FIGURE 20 is a fragmentary enlarged vertical sectional view, taken on line 20-20 of FIGURE 19, and illustrates horizontal edge portions of the container having four thicknesses of material at the ends thereof.

FIGURE 21 is an enlarged fragmentary vertical sectional view, taken on line 2121 of FIGURE 19, and illustrates a recessed end panel with outwardly extending flanges having four thicknesses of material.

FIGURE 22 is an enlarged fragmentary sectional view, taken on line 22-22 of FIGURE 20, and illustrates a corner construction at the intersection of a side panel and a recessed end panel.

FIGURE 23 is an enlarged fragmentary sectional view, similar to FIGURE 20, and illustrates a modified construction of an edge portion of a container.

FIGURE 24 is a perspective view of another embodiment of this invention, and illustrates a closed container which is constructed from four separate pieces of material.

FIGURE 25 is a perspective view, similar to FIGURE 24, and illustrates the container with the closure flaps in a partially opened position.

FIGURE 26 is an enlarged fragmentary vertical sectional view, taken on line 26-26 of FIGURE 24, and illustrates one manner of forming a recessed end panel and flange construction.

FIGURE 27 is an enlarged fragmentary view, taken on line 2727 of FIGURE 24, and illustrates a double thickness vertical flange.

FIGURE 28 is an enlarged fragmentary vertical sectional view, taken on line 2828 of FIGURE 24, and illustrates a closure flap which has an ear integrally connected thereto for strengthening an edge portion of the container.

FIGURE 29 is a plan view of a composite four-piece blank for constructing the carton shown in FIGURE 24.

FIGURE 30 is a fragmentary perspective view of a modified form of a container having an internal closure 4 flap and an integrally connected reversely turned ear for strengthening an edge portion of a container.

FIGURE 31 is an enlarged fragmentary perspective View, similar to FIGURE 30, and illustrates a modified manner of positioning the closure flap and ear.

FIGURE 32 is a fragmentary sectional view of a container flange constructed in accordance with the present invention, and illustrates a wood insert for reinforcing the flange.

FIGURE 33 is a fragmentary sectional view of a container flange, similar to FIGURE 32, and illustrates a metal rod for reinforcing the container flange.

Referring to the drawings in detail, there is illustrated in FIGURE 1 a corrugated cardboard blank, generally indicated by the numeral 10, from which a container 11 is constructed as shown in FIGURES 2 through 6. The blank 10 is substantially rectangular and includes a first side panel 12, a first end panel 13, a second side panel 14 and a second end panel 15.

The side panel 12 is provided with closure flaps 16 and 17 which are attached to the side panel 12 along longitudinal edge portions thereof, which edge portions are defined by longitudinally extending fold lines 18 and 19. The side panel 12 is also provided with a flange forming panel 20 and a closure tab 21. The flange forming panel 20 is attached to the side panel 12 along a transversely extending fold line 22, and the closure tab 21 is attached to the flange forming panel 20 along a transversely extending fold line 23.

The first end panel 13 is spaced from the side panel 12 by a flange forming panel 24 which is attached to the side panel 12 along a transverse fold line 25 and to the end panel 13 along a transverse fold line 26. The end panel 13 is also provided with a pair of longitudinally extending flange forming panels 27 and 28 and a pair of closure flaps 29 and 30. The flange forming panel 27 is attached to the end panel 13 along a longitudinally extending fold line 31, and the flange forming panel 28 is attached to the side panel 13 along a longitudinally extending fold line 32. The closure flap 29 is attached to the flange forming panel 27 along a longitudinally extending fold line 33 and the closure flap 30 is attached to the flange forming panel 28 along a longitudinally extending fold line 34.

The second side panel 14 is offset from the end panel 13 by a transversely extending flange forming panel 35 which is attached to the end panel 13 along a transverse fold line 36 and to the side panel 14 along a transverse fold line 37. The side panel 14 is provided with a pair of closure flaps 38 and 39. The closure flap 38 is attached to the side panel 14 along a longitudinally extending fold line 40 and the closure flap 39 is attached to the side panel 14 along a longitudinally extending fold line 41.

The second end panel 15 is offset from the side panel 14 by a transversely extending flange forming panel 42 which is attached to the side panel 14 along a transverse fold line 43 and to the end panel 15 along a transverse fold line 44. The end panel 15 is provided with a pair of longitudinally extending flange forming panels 45 and 46, a pair of closure flaps 47 and 48, and a transversely extending flange forming panel 49. The flange forming panel 45 is attached to the end panel 15 along a longitudinally extending fold line 50 and is attached to the closure flap 47 along a longitudinally extending fold line 51. The flange forming panel 46 is attached to the end panel 15 along a longitudinally extending fold line 52 and is attached to the closure flap 48 along a longitudinally extending fold line 53. Completing the blank 10, the flange forming panel 49 is attached to the end panel 15 along a transverse fold line 54.

When constructing the container 11 from the blank 10, the blank is folded along the transverse fold line 22 such that the flange forming panel 20 and closure tab 21 are disposed in abutting relation with the side panel 12. The

- blank 10 is then folded along the transverse fold line 37 forming panel 20, and a portion of the end panel 15 adjacent to the fold line 54 overlies the closure tab 21. With the blank in the folded position just described, the closure tab 21 is secured to the end panel 15, the flange forming panel 49 is secured to the flange forming panel 28 which is in turn secured to the side panel 12, and the flange forming panel 35 is secured to'the side panel 14. It is preferable that the closure tab 21 be fixedly secured to the end panel by the use of glue or other suitable adhesive and that wire stitching or staples, such as shown at 55, be used to fixedly secure the flange forming panels 49 and to the side panel 12 and to secure the flange forming panel 35 to the side panel 14.

Upon completion of the above described securing operations, the partially constructed container 11 is opened and then reclosed such that the side panel 12 overlies the end panel 13, and the end panel 15 overlies the side panel 14, as clearly shown in FIGURE 2. With the partially constructed container 11 being in the position shown in FIGURE 2, wire stitching or wire staples 55 are used to secure the flange forming panel 452 to the side panel 14 and to secure the flange forming panel 24 to the side panel 12. The longitudinally extending flange forming panels 27, 2-8, 45 and 46 are then preferably but not necessarily glued or otherwise secured to their respective closure flaps 29, 38, 47 and 48, respectively. The last mentioned securing operation may be performed by either the manufacturer or by the customer. Of course, the container is shipped to the customer in a flat folded form, such as is shown in FIGURE 2, and the container 11 is erected, such as is shown in FIGURE 3, just prior to use.

As is clearly shown in FIGURES 5 and 6, the cutting, scoring and folding of the corrugated blank 18 results in the formation of a substantially I-beam shape at each end of the container 11. It should be noted that the strength for vertical support of weight at each end of the container 11 is obtained not only as the result of the Lbeam shape but also as a result of the vertical flanges. In addition, when the container 11 is to be constructed of corrugated cardboard, the blank 18 is cut from the cardboard stock such that the flutes of the corrugations are vertically disposed in the side panels, recessed end panels and vertical flanges as is shown at 56 in FIGURE 6. In addition to the vertical strength which permits a large number of containers 11 to be stacked on top of each other, merchandise in the container 11 is protected by the vertical and horizontal flanges whenever the container and its contents are dropped. In shipping pieces of floor tile, for example, it has been found that the greatest damage occurs at the corners whenever the container is dropped. By providing the container 11 with the re cessed end panels 13 and 15 and by providing the vertical and horizontal flanges which circumscribe these end panels, damage of the above described type is very substantially lessened.

Considering the sectional view which is illustrated in FIGURE 6, it will be apparent that the flange forming panel 20 and closure tab 21 may be dispensed with, and if preferred, the container 11 may be modified such that the flange forming panel 49 is stitched or stapled directly to the side panel 12. This modification, which is within the scope of the present invention, would reduce the number of internal raw edges disposed within the container.

Referring to FIGURES 7 through 11, a modified container blank, generally indicated by the numeral 68, is illustrated in FIGURE 7 and is used in constructing a container, generally indicated by the numeral 61 as is shown in FIGURES 8 through 11.

The container blank 60 is substantially rectangular and is provided at one longitudinal end thereof with an outwardly extending flange forming panel 62 and is provided at the other longitudinal end thereof with a pair of outwardly extending extensions or ears 63 and 64. The blank 60 includes a first side panel 65, a first end panel 66, a second side panel 67 and a second end panel 68.

A first pair of closure flaps 69 and 70 are connected to the first side panel 65 along longitudinally extending fold lines 71 and 72, respectively. The previously mentioned ear 63 is attached to the closure flap 69 along a transverse fold line 73, and a second ear 74 is connected to the closure flap 69 along a transverse fold line 75. The previously mentioned ear 64 is attached to the closure flap 70 along a transverse fold line 76 and a second ear 77 is attached to the closure flap 70 along a transverse fold line 78.

The end panel 66 is offset from the side panel 65 by a transversely extending flange forming panel 79 which is attached to the side panel 65 along a transverse fold line 80 and which is attached to the end panel 66 along a transverse fold line 81. The end panel 66 is provided with a pair of longitudinally extending flange forming panels 82 and 83 which are attached to the end panel 66 along longitudinally extending fold lines 84 and 85, respectively. A closure flap 86 is connected to the flange forming panel 82 along a longitudinally extending fold line 87, and a closure flap 88 is connected to the flange forming panel 83 along a longitudinally extending fold line 89. The car 74 is separated by a severance line W from the flange forming panel 82 and from the closure flap 86. The ear 77 is separated by a severance line 91 from the flange forming panel 83 and from the closure flap 88.

The second side panel 67 is offset from the end panel 66 by a transversely extending flange forming panel 92 which is connected to the end panel 66 along a transverse fold line 93 and to the side panel 67 along a transverse fold line 94. The sec-0nd side panel 67 is provided with a pair of closure flaps 95 and 96 which are connected thereto along longitudinal fold lines 97 and 98, respectively. A pair of ears 99 and 188 are attached to the closure flap 95 along transverse fold lines 101 and 182, respectively. The closure flap 96 is provided with a pair of extensions or ears 183 and 104 which are connected thereto along transverse fold lines 185 and 186, respectively. The blank 60 is cut along a severance line 107, to separate the ear 99 from the flange forming panel 82 and closure flap 86, and is cut along a severance line 108 to separate the ear 103 from the flange forming panel 83 and closure flap 88.

The second end panel 68 is offset from the second side panel 67 by a transversely extending flange forming panel 189 which is connected to the side panel 67 along a transverse fold line 118 and to the end panel 68 along a transverse fold line 111. The end panel 68 is provided with a pair of longitudinally extending flange forming panels 112 and 113 which are connected to the end panel 68 along fold lines 114 and 115, respectively. A closure flap 116 is attached to the flange forming panel 112 along a fold line 117, and the blank 68 is cut along a severance line 118 for separating the ear from the flange forming panel 112 and closure flap 116. A closure flap 119 is attached to the flange forming panel 113 along a fold line 120, and the blank 68 is cut along a severance line 121 to separate the ear 184 from the flange forming panel 113- and closure flap 119. Completing the container blank 60, the previously mentioned flange forming panel 62 is attached to the end panel 68 along a transverse fold line 122.

When constructing the container 61 from the container blank 60, the blank is initially folded along the longitudinal fold lines 87 and 89 such that the closure flaps 86 and 88 overlie the end panel 66. The closure flaps 86 and 88 are then, if so desired, secured to their respective flange forming panels 82 and 83 by the use of suitable adhesives, or wire stitching or staples 123. The blank 60 is then folded along the transverse fold line 94 such that the side panel 65 is brought into overlying relation with the flange forming panel 62 and end panel 68, as is shown in FIGURE 8. A marginal edge of the side 7 panel 65 is then secured to the flange forming panel 62, such as by the stitching or staples 123, and the flange forming panel 92 is secured to the side panel 67, with the use of stitching or staples 123.

An alternative manner of folding the container blank 60 to form the container 61 is illustrated in FIGURE 8A. Instead of initially folding the blank 60 along the fold lines 87 and 89, the blank 60 may simply be folded along the transverse fold lines 94 such that the side panel 65 is brought into overlying relation with the flange forming panel 62 and end panel 68. Either of these methods of folding the blank 60 will produce a flap-folded container 61; however, with the closure flaps 86 and 88 folded inwardly as illustrated in FIGURE 8, the container 61 will fold more easily than if the closure flaps 86 and 88 are left in coplanar relation with the end panel 66, as is shown in FIGURE 8A.

As can be seen in FIGURE 9, the end panel 66 is recessed inwardly of the container 61 and the end panel is circumscribed by horizontal and vertical flanges extending outwardly therefrom. The opposite end panel 68, not shown in FIGURE 9, is likewise recessed inwardly of the container 61 and is circumscribed by horizontal and vertical flanges.

In FIGURE 10, there is illustrated one manner of utilizing the various ears, such as the cars 74 and 77. As is shown, the cars 74 and 77 are wrapped around the flanges which are formed by the flange forming panels 82 and 83, and then are suitably fastened thereto by such means as the stitching or staples 123. Thus, it can be seen that the recessed end panel 66 has been provided with outwardly extending, upper and lower horizontal flanges of quadruple thickness.

FIGURE 12 illustrates an alternative manner of utilizing the various cars, such as the ear 74. In this form, the ear 74 is folded so as to be in engagement with its respective closure flap 69 rather than to be in engagement with the flange forming panel 82. Whether the ear 74 is folded as is shown in FIGURE 10, or as shown in FIG- URE 12, the recessed end panel 66 is provided with an outwardly extending flange which is of quadruple thickness. It is clear, that the flange which is shown in FIG- URE 12 may be secured together by a suitable adhesive or by the stitching or staples 123.

In FIGURE 13, there is illustrated a modified form of container construction wherein the outwardly extending horizontal flanges are of triple thickness rather than quadruple thickness as previously described. It will be clear from a comparison of FIGURES 12 and 13 that the triple thickness flange is obtained by merely omitting the ears, such as the car 74. Thus, a container with triple thickness flanges may be constructed from the container blank 60, as is shown in FIGURE 7, by merely omitting the various ears 63, 64, 74, 77, 99, 100, 103 and 104.

In FIGURE 14, there is illustrated a modified form of container wherein the outwardly extending horizontal flanges are of double thickness. A comparison of FIG- URES 12 and 14 will make it clear that a double thickness is obtained by merely omitting the flange forming panels, such as the flange forming panel 82. In this modified form, the flange forming panels 82, 83, 112 and 113 are omitted from the container blank 60 such that the closure flaps 86, 88, 116 and 119 are directly connected to their respective end panels 66 and 68.

In FIGURE 15, there is illustrated another modified form of container in which the outwardly extending horizontal flanges are of single thickness. It will be clear from a comparison of FIGURES 14 and 15 that a single thickness flange is obtained by omitting the various cars, such as the ear 74. Thus, in order to construct a container such as is illustrated in FIGURE 15, the container blank 60 may be modified by omitting each of the transversely extending ears and each of the longitudinally extending flange forming panels.

Illustrated in FIGURE 16 is a modified container blank, generally indicated by the numeral 130, which is used in constructing a container 131 which is illustrated in FIGURES 17 through 22. The container blank includes a first side panel 132, a first end panel 133, a second side panel 134, and a second end panel 135.

The first side panel 132 is provided with a pair of closure flaps 136 and 137 which are connected to the side panel 132 along a pair of parallel longitudinally extending fold lines 138 and 139, respectively.

The first end panel 133 is offset from the first side panel 132 by a transversely extending flange forming panel 140 which is connected to the side panel 132 along a transverse fold line 141 and to the end panel 133 along a transverse fold line 142. The end panel 133 is provided with a pair of longitudinally extending flange forming panels 143 and 144, and with a pair of closure flaps and 146. The flange forming panels 143 and 144 are attached to the end panel 133 along longitudinal fold lines 147 and 148, respectively, and the closure flaps 145 and 146 are attached to the flange forming panels 143 and 144 along parallel fold lines 149 and 150, respectively.

The closure flap 145 is provided with a pair of transversely extending ears 151 and 152 which are attached thereto along transverse fold lines 153 and 154, respectively. A pair of transversely extending ears 155 and 156 are likewise provided for the closure flap 146 and are attached thereto along a pair of transverse fold lines 157 and 158, respectively. The ears 151 and 155 are separated from the adjacent closure flaps 136 and 137 by transverse severance lines 159 and 160, respectively. A corner tab 161 is attached to the flange forming panel 140 along the fold line 138 and is further bounded by the fold line 141 and a pair of severance lines 162 and 163. A corner tab 164 is attached to the flange forming panel 140 along the fold line 139 and is further bounded by the fold line 141 and a pair of severance lines 165 and 166.

A transversely extending flange forming panel 167 is attached to the end panel 133 along a transverse fold line 168 and is further defined by the fold lines 147, 148 and a transverse fold line 169. A corner tab 170 is connected to the flange forming panel 167 along the fold line 147, and a corner tab 172 is connected to the flange forming panel 167 along the fold line 148. The corner tab 170 is further defined by the fold line 169 and a pair of severance lines 173 and 174. The corner tab 172 is further defined by the fold line 169 and a pair of severance lines 175 and 176. The first half of the container blank 130 is completed by a severance line 177, which defines an edge of the ear 152 and by a severance line 178 which defines an edge of the ear 156.

The half of the container blank 130 which includes the second side panel 134 and the second end panel 135 is identical to that half of the container blank 130 previously described. The second side panel 134 is provided with a pair of closure flaps 180 and 181, and is connected to the second end panel 135 by a flange forming panel 182.

The end panel 135 is provided with a pair of longitudinally extending flange forming panels 183 and 184 which are in turn connected to closure flaps 185 and 186, respectively. A pair of transversely extending ears 187 and 188 are attached to the closure flap 185, and ears 189 and 190 are attached to the closure flap 186.

A flange forming panel 191 is attached to the end panel 135 along the edge thereof which is opposite from the flange forming panel 182. The flange forming panel 182 is provided with a pair of corner tabs 192 and 193, and the flange forming panel 191 is provided with a pair of corner tabs 194 and 195.

The container 131, in the flat folded position as is shown in FIGURE 17, is constructed by folding the blank 130 along the central fold line 169. The side panel 132 is brought into overlying relation with the end panel 135 and is preferably adhesively secured to the flange forming panel 191 and the corner tabs 194 and 195. In the fully erected form, as is shown in FIGURES 18 through 22, each of the small corner tabs is adhesively secured to the closure flap on the adjacent side panel. The closure flaps 136, 137, 180 and 181 are folded inwardly and then are enclosed by the closure flaps 145, 146, 185 and 186. Each of the eight ears is then adhesively secured to the adjacent one of the side panels 132 and 134 to form the completely erected container 131, as is shown in FIGURE 19.

The completed container 131 provides a completely smooth interior which fits the contents closely in every place to prevent shifting and rubbing. The container 131 is also provided with ready-made hand grips which are formed by the flanges which extend outwardly from the recessed end panels, as is shown at 184 in FIGURE 21. Also, the container 131 is provided with top and bottom floors which are of uniform double thickness because the opposing closure flaps just meet. Further, the container 131 includes eight flange-protected edges with four layers of material on edge protecting the extreme corners of the box, and the four remaining edges are protected by double thickness because of the wraparound ears.

The various ears, such as the ears 188 and 190 in FIGURE 20, have been described as being adhesively secured to a respective side panel. However, as is shown in FIGURE 23, it may be preferable to fold the ears, such as the ear 1%, inwardly into engagement with the respective closure flap.

As described above, the present invention is adaptable with great advantage to one-piece container construction, but it also permits the assembly of four pieces into strong containers having smooth interiors. Each of the four pieces could be substantially a rectangle, and since each could be cut to optimum length before assembly, there would be no wastefully long flaps, and scrap would be minimized. As is shown in FIGURE 29, a four-piece composite blank, generally indicated by the numeral 219, is provided for contsructing the container, generally indicated by the numeral 211, which is illustrated in FIG- URES 24 through 2.8. I

In FIGURE 29, the blank 210 includes a pair of end portions 212 and 213, and a pair of side portions 214 and 215 which are positioned in edge alignment along the line 216.

The end portion 212 includes an end panel 220, a first pair of flange forming panels 221 and 222, and a pair of closure flaps 223 and 224. The flange forming panels 221 and 222 are attached to the end panel 22d along fold lines 225 and 226 respectively. The closure flap 223 is connected to the flange forming panel 221 along a fold line 227, and the closure flap 224 is connected to the flange forming panel 222 along a fold line 228. The end panel 220 is also provided with a second pair of flange forming panels 229 and 230 which are attached thereto along fold lines 231 and 232, respectively. Ears 233 and 234 are attached to the closure flap 224 along a pair of fold lines 235 and 236, respectively. 7

The end portion 213 is identical to the end portion 212 and includes an end panel 240, a first pair of flange forming panels 241 and 242, a second pair of flange forming panels 243 and 244, a pair of Closure flaps 245 and 246, and a pair of cars 247 and 248 which are attached to the closure flap 246.

It is also within the scope of this invention that ears may be provided along the parallel free edges of the closure flaps 223 and 245 or, if desired, the various ears on the closure flaps 224 and 246 may be omitted.

The side portion 214 includes a side panel 250 and a pair of closure flaps 251 and 252 which are attached to the side panel 250 along fold lines 253 and 254, respectively. The side portion 215 is identical to the side portion 214 and includes a side panel 255 and a pair of closure flaps 256 and 257 which are attached to the side panel 255 along a pair of fold lines 258 and 259, respectively.

In constructing the container 211 from the composite four-piece blank 210, the end portions 212 and 213 are 10 attached to the side portions 214 and 215 as is illustrated in FIGURES 24 through 28. The four pieces of the blank 210 may be adhesively secured together but, as is shown, it is preferably to use stitching or staples 260.

One alternative manner of forming the container 211 is illustrated by the top portion of the containers in FIG- URES 24 and 25. The closure flaps 223 and 245, on the end panels 220 and 240, are folded inwardly so as to just met at a center line 261 and, then, the closure flaps 251 and 256 are folded into their closed positions, as is shown in FIGURE 24.

As is shown at the bottom portion of the container 211, in FIGURES 24 through 28, the closure flaps 224 and 246, of the end panels 220 and 240, may be disposed outwardly from the closure flaps 252 and 256 of the side panels 25!) and 255. When this form of folding is used the ears 233, 234, 247 and 248 are fastened with a suitable adhesive to the upstanding side panels 250 and 255.

Thus, it has been shown that the closure flaps on the end panels or the closure flaps on the side panels may either be inner flaps or outer flaps. It is also apparent that the inner flaps need not necessarily meet at the center of the container but may be made shorter as is indicated by the broken lines in the closure flaps 223 and 245, as is shown in FIGURE 2.9. Thus, the closure flaps may be of unequal length and economical use of materials is possible. For that matter, the material which is used to form the side panels 251i and 255 may be different than the material which is used to form the end panels 220 and 242, or the same material may be used but in different grain directions. These advantages derive from the possibility of any or all flanges being joints or seams without introduction of corner weakness or internal raw edges.

It is shown in FIGURE 30 that what usually is an inner flap can also he used as an outer flap. Thus, the closure flap 257, on the side panel 255, may be disposed outwardly from the closure flap 224. In this form, the car 234 is folded along the fold line 236 so as to be disposed between the closure flap 224 and the closure flap 257.

Another way of folding the container blank 211i is illustrated in FIGURE 31. For added strength and corner protection, the various ears, such as the ear 234, may be adhesively secured to the upstanding side panels 250 and 255.

Illustrated in FIGURES 32 and 33, are two possible ways for providing the various containers with greater strength by providing various reinforcing means for either the vertical or horizontal flanges.

As is shown in FIGURE 32, a recessed end panel 270 is provided with a flange forming panel 271 and with what may be either a closure flap or a side panel 272. The panels 271 and 272 are spaced frompeach other and receive therebetween a reinforcing means such as the wood insert 273.

FIGURE 33 is similar to FIGURE 32 and illustrates a recessed end panel 275, and a closure flap or side panel 276 which is connected to the panel 275 by a flange forming panel 277. The outwardly extending flange which is formed vby these various panels is reinforced by a metal wire or rod 278.

It is apparent from the foregoing that there has been disclosed various types of containers each of which comprise a plurality of upstanding panels including side panels and recessed end panels. The containers also include first closure flaps which are connected to the side panels along the top and bottom edges thereof, and second closure flaps which are connected to the end panels along the top and bottom edges thereof. Also, each of the containers is constructed such that edge portions of the first closure flaps and edge portions of the side panels extend outwardly from the recessed end panels to provide outwardly extending flanges therefor.

Each of the various containers is preferably constructed of corrugated cardboard in a manner such that the flutes thereof are vertically disposed in each of the upstanding side panels, recessed end panels and vertically d1sposed flanges. However, it is apparent, that the various containers could be constructed of paperboard, heavy paper, plastic or other similar flexible materials.

While preferred forms and arrangement of parts have been shown in illustrating the invention, it is to be clearly understood that various changes in details and arrangement of .parts may be made without departing from the spirit and scope of the invention as defined in the appended claimed subject matter.

I claim:

1. A container comprising a plurality of upstanding panels including a pair of side panels and a pair of recessed end panels, each of said end panels being of rectangular shape and being provided along the edges thereof with integrally connected and outwardly extending flange forming panels, said upstanding side panels having end portions that overlie adjacent ones of said flange forming panels, first closure flaps formed integrally with said side panels along the top and bottom edges thereof, and second closure flaps integrally formed with upper and lower ones of said flange forming panels; said first closure flaps being provided along opposite edges thereof with integrally attached ears, said first closure flaps being disposed outwardly of said second closure flaps, said ears being reversely folded and disposed between said first closure flaps and said second closure flaps, whereby said container is provided with a quadruple-thickness flange.

2. A container comprising a plurality of upstanding panels including a pair of side panels and a pair of recessed end panels, said side panels having vertical edges extending outwardly from said recessed end panels, first closure flaps integrally connected to said side panels along the top and bottom edges thereof, the first closure flaps on one of said side panels and the first closure flaps on the other of said side panels being disposed in coplanar relationship and extending toward each other for substantially one-half the width of said end panels, second closure flaps extending inwardly from said recessed end panels and underlying said first closure flaps, said first closure flaps extending outwardly of said recessed end panels to provide horizontally disposed and vertically spaced flanges for said container, said first closure flaps being provided with reversely turned inwardly directed ears, whereby said container is provided with a double thickness flange along top and bottom edges of said recessed end panels.

3. A container blank comprising a pair of side panels, a first end panel connected to and longitudinally spacing said side panels from each other, and a second end panel attached to one of said side panels along a transverse edge thereof, each of said side panels having first closure flaps integrally connected thereto along longitudinal edges thereof, each of said first and second end panels having flange forming panels integrally connected thereto along longitudinal edges thereof, and second closure flaps connected to each of said flange forming panels; each of said second closure flaps having a pair of transverse edges, and each of said edges being provided with an ear extending therealong and integrally connected thereto; said first and second end panels being provided along each transverse edge thereof with flange forming panels, and tabs connected to each end of said flange forming panels.

4. A container comprising a plurality of upstanding panels including a pair of side panels and a pair of recessed end panels, said side panels having vertical edges extending outwardly from said end panels, first closure flaps integrally connected to said side panels along the top and bottom edges thereof, each of said end panels being provided with vertically disposed flange forming panels connecting said end panels to said side panels, each of said end panels being provided with horizontally disposed flange forming panels and with second closure flaps, and said container being provided with tabs at each corner thereof; whereby said tabs, said first and second closure flaps and said horizontally disposed flange forming panels provide quadruple thickness corner portions for said container.

5. A container comprising a plurality of upstanding panels including a pair of side panels and a pair of recessed end panels, said side panels having vertical edges extending outwardly from said end panels, first closure flaps integrally connected to said side panels along the top and bottom edges thereof, each of said end panels being provided with vertically disposed flange forming panels connecting said end panels to said side panels, each of said end panels being provided with horizontally disposed flange forming panels and with second closure flaps, and said container being provided with tabs at each corner thereof; whereby said tabs, said first and second closure flaps and said horizontally disposed flange forming panels provide quadruple thickness corner portions for said container; said second closure flaps being provided along opposite edges thereof with integrally attached ears, said ears being vertically disposed and adhesively secured to said side panels.

6. A container comprising a plurality of upstanding panels including a pair of side panels and a pair of recessed end panels, said side panels having vertical edges extending outwardly from said end panels, first closure flaps integrally connected to said side panels along the top and bottom edges thereof, each of said end panels being provided with vertically disposed flange forming panels connecting said end panels to said side panels, each of said end panels being provided with horizontally disposed flange forming panels and with second closure flaps, and said container being provided with tabs at each corner thereof; whereby said tabs, said first and second closure flaps and said horizontally disposed flange forming panels provide quadruple thickness corner portions for said container; said second closure flaps being provided along opposite edges thereof with integrally attached ears, said ears being reversely folded so as to lie adjacent to said second closure flaps, whereby said container is provided with corner portions of five thicknesses.

7. A composite blank for a container, said blank comprising separate side and end portions; each side portion including a side panel, and first closure flap means integrally connected to said side panel; each end portion including an end panel and second closure flap means integrally connected to said side panel; and flange forming panels integrally connected to opposite edges of said end panels; said second closure flap means being provided along opposite edges thereof with ears integrally connected thereto.

8. A container constructed of a pair of side portions and a pair of end portions; each of said side portions including an upstanding side panel, and first closure flap v integrally connected to said side panel along the top and bottom edges thereof; each of said end portions including an upstanding end panel, flange forming panels integrally connected to said end panel along opposite edges thereof, and second closure flaps connected to said end panel by said flange forming panels; said second closure flaps being provided along opposite edges thereof with car integrally connected thereto, said second closure flap being disposed outwardly of said first closure flaps, and said ears being adhesively secured to said side panels.

9. A container constructed of apair of side portions and a pair of end portions; each of said side portions including an upstanding side panel, and first closure flaps integrally connected to said side panel along the top and bottom edges thereof; each of said end portions including an upstanding end panel, flange forming panels integrally connected to said end panels along opposite edges thereof, and second closure flaps connected to said end panel by said flange forming panels; said second closure flaps being provided along opposite edges thereof with ears integrally connected thereto, said first closure flaps being.

disposed outwardly of said second closure flaps, and said ears extending parallel to said second closure flaps.

10. A container constructed of a pair of side portions and a pair of end portions; each of said side portions including an upstanding side panel, and first closure flaps integrally connected to said side panels along the top and bottom edges thereof; each of said end portions including an upstanding end panel, flange forming panels integrally connected to said end :panel along opposite edges thereof, and second closure flaps connected to said end panel by said flange forming panels; said second closure flaps being provided along opposite edges thereof With ears integrally connected thereto, said first closure flap being disposed outwardly of said second closure flaps, and said ears extending parallel to said side panels.

References Cited by the Examiner UNITED STATES PATENTS JOSEPH R. LECLAIR, Primary Examiner.

DAVID M. BOCKENEK, Examiner. 

1. A CONTAINER COMPRISING A PLURALITY OF UPSTANDING PANELS INCLUDING A PAIR OF SIDE PANELS AND A PAIR OF RECESSED END PANELS, EACH OF SAID END PANELS BEING OF RECTANGULAR SHAPE AND BEING PROVIDED ALONG THE EDGES THEREOF WITH INTEGRALLY CONNECTED AND OUTWARDLY EXTENDING FLANGE FORMING PANELS, SAID UPSTANDING SIDE PANELS HAVING END PORTIONS THAT OVERLIE ADJACENT ONES OF SAID FLANGE FORMING PANELS, FIRST CLOSURE FLAPS FORMED INTEGRALLY WITH SAID SAID PANELS ALONG THE TOP AND BOTTOM EDGES THEREOF, AND SECOND CLOSURE FLAPS INTEGRALLY FORMED WITH UPPER AND LOWER ONES OF SAID FLANGE FORMING PANELS; SAID FIRST CLOSURE FLAPS BEING PROVIDED ALONG OPPOSITE EDGES THEREOF WITH INTEGRALLY ATTACHED EARS, SAID FIRST CLOSURE FLAPS BEING DISPOSED OUTWARDLY OF SAID SECOND CLOSURE FLAPS, SAID EARS BEING REVERSELY FOLDED AND DISPOSED BETWEEN SAID FIRST CLOSURE FLAPS AND SAID SECOND CLOSURE FLAPS, WHEREBY SAID CONTAINER IS PROVIDED WITH A QUADRUPLE-THICKNESS FLANGE. 